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Clutch Engagement System: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the clutch actuator lever bushings.
    NOTE: One clutch actuator lever bushing shown in illustration, one per clutch actuator lever.
    Fig 1: Locating Clutch Actuator Lever Bushings
    G06939315Courtesy of FORD MOTOR CO.
  2. Install the clutch actuator lever 2.
    NOTE: Be sure to properly handle the actuator lever as shown in illustration or damage may occur.
    Fig 2: Locating Clutch Actuator Lever
    G06939316Courtesy of FORD MOTOR CO.
  3. Install clutch motor 2 without the bolts to aide in the alignment of the clutch actuator lever.
  4. Install the 2 clutch actuator lever 2 bolts.
    • Tighten to 19 Nm (168 lb-in).
      Fig 3: Locating Clutch Actuator Lever Bolts
      G06939317Courtesy of FORD MOTOR CO.
  5. Install the clutch actuator lever 1.
    NOTE: Be sure to properly handle the actuator lever as shown in illustration or damage may occur.
    Fig 4: Locating Clutch Actuator Lever
    G06939318Courtesy of FORD MOTOR CO.
  6. Install clutch motor 1 without the bolts to aide in the alignment of the clutch actuator lever.
  7. Install the 2 clutch actuator lever 1 bolts.
    • Tighten to 19 Nm (168 lb-in).
      Fig 5: Locating Clutch Actuator Lever Bolts
      G06939319Courtesy of FORD MOTOR CO.
  8. Install the spring retainers and spring retainer bolts.
    NOTE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or damage can occur to the clutch actuator levers.
    NOTE: Make sure the spring retainer contour aligns with the actuator lever contour as shown in illustration.
    NOTE: Make sure the serial number on the spring retainer matches the serial number on the actuator lever. If reusing the spring retainers and actuator levers use the marks made during removal for assembly.
    • Tighten to 26 Nm (19 lb-ft).
      Fig 6: Locating Spring Retainer Bolts
      G06939320Courtesy of FORD MOTOR CO.
  9. Remove the clutch actuator lever locks if installed.
    Fig 7: Locating Clutch Actuator Lever Locks
    G06939321Courtesy of FORD MOTOR CO.
  10. Install the clutch motors. For additional information, refer to CLUTCH MOTOR - NO. 1  and CLUTCH MOTOR - NO. 2  in this information.
  11. Install the engagement system bearing unit.
    NOTE: The engagement system bearing unit should be installed easily.
    Fig 8: Installing Engagement System Bearing Unit
    G06939322Courtesy of FORD MOTOR CO.
  12. Install the Z-washers onto the engagement system bearing unit and center them correctly.
    NOTE: Do not tilt transaxle after the Z-washers are installed, they may come off center and damage can occur.
    Fig 9: Locating Z-Washers
    G06939323Courtesy of FORD MOTOR CO.
  13. Install the clutch. For additional information, refer to CLUTCH  in this information.
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